Marine decking with sandwich-type consruction and method of making same

ABSTRACT

A marine deck member with enhanced surface traction and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be effected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be effected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 13/479,974, filed May 24, 2012 (pending), and U.S. Ser. No. 13/762,879, filed Feb. 8, 2013 (pending) the disclosures of which are hereby incorporated in their entirety by reference herein. This application is also related to U.S. Ser. No. 14/603,418, filed Jan. 23, 2015 (now U.S. Pat. No. 9,567,037, issued Feb. 14, 2017); and Ser. No. 13/517,877, filed Jan. 14, 2012 (Abandoned).

TECHNICAL FIELD

This invention relates to marine decking for use with pontoon boats, docks, rafts, swim platforms, watercraft docking stations and the like, and methods for making the same.

BACKGROUND

The surfaces of boat decks, swim platforms, docks and similar marine structures are commonly made of fiberglass, aluminum, treated plywood, vinyl or perforated rubber. These surfaces are subjected to sun light/heat, rain, humidity, etc. in harsh marine service environments. These materials can deteriorate and require repair or replacement over extended periods of use.

Another factor is these materials can be slippery. Prior efforts to provide non-slip marine surfaces are found in U.S. Pat. No. 4,737,390, for Non-Slip Coating for Molded Articles, and Pub. No. US 2013/0233228, for Porous Anti-Slip Floor Covering. In U.S. Pat. No. 4,737,390 a layer of latex or latex-impregnated sheet material is adhered to molded thermoset plastic article while curing in the mold. FIG. 4 illustrates the application of this sheet material in a boat deck. In Pub. No. US 2013/0233228 a porous anti-slip floor covering uses a layer of curled strands placed on an underlayment.

Factors affecting the suitability of a material for marine deck applications, in addition to the ability to withstand the environmental factors above, include cost, weight, strength, traction and buoyancy.

SUMMARY

The marine deck materials of the present invention utilize sandwich-type, compression-molded, composite components. Sandwich-type composite panels including cores have very important characteristics because of their light weight and high strength. Such panels are constructed by sandwiching a cellular core having low strength characteristics between two outer plastic layers or skins, each of which is much thinner than the core but has excellent mechanical characteristics. The core is made of a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins.

Sandwich-type composite panels are conventionally made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The stack is made up of, at least: a first skin of plastic material, a cellular core, and a second skin also of plastic material. The stack may be pre-heated outside the mold or heated inside the mold to a softening temperature. Once the stack is placed in the mold, the closing of the mold halves causes the inner surfaces of the softened skins to bond to the mating faces of the core.

In one embodiment, the sandwich-type composite panel has a first skin of thermoplastic material, a second skin of thermoplastic material, and a cellular core of thermoplastic material positioned between the skins. The skins are bonded to the core by press molding. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins.

In another embodiment, the sandwich-type composite panel has a first skin of a fiber-reinforced thermoplastic material, a first sheet of thermoplastic adhesive, a second skin of fiber-reinforced thermoplastic material, a second sheet of thermoplastic adhesive and a cellular core of a cellulose-based material positioned between the skins. The skins are bonded to the core by the first and second adhesive sheets and by press molding. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins.

The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled (i) debossing, or (ii) embossing, of the first, outer skin while it cools in the compression mold. The air in the core cavities causes thermal gradients relative to the cell walls that result in uneven cooling over the surface area of the skin. The resultant uneven cooling is manifested as “debossing” (or, “sink marks”) on the surfaces of the skins. The phenomenon of debossing can be used advantageously to enhance surface traction of the outer surface of the first skin.

The debossing effect can be accentuated by applying pressurized gas, e.g., pressurized nitrogen or air, onto the outer surface of the first skin as it cools in the compression mold.

Alternatively, the uneven cooling phenomenon can be used to “emboss” the surface of the skin be application of vacuum pressure while the skin is cooling in the mold. The embossments are raised surfaces that also enhance surface traction on the outer surface of the first skin.

The debossing/embossing pattern on the outer surface can be defined by the cross-sectional shape of the cells. Cells of circular cross-sectional will produce circular debossments/embossments; cells of honeycomb shape will produce hexagonal debossments/embossments; and cells of cleated shape will produce cleat-shaped debossments/embossments.

The invention provides marine deck materials that have a relatively high strength-to-weight ratio, buoyancy, and enhanced surface traction. These properties make these deck materials suited for use in such applications as boat decks, swim platforms, docks and similar marine structures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pontoon deck as a representative product application of the present invention;

FIG. 2A is an enlarged view of the pontoon deck surface, encircled as “2A” in FIG. 1, showing debossments matching the cross-sectional shape of the circular cells in the core;

FIG. 2B is an enlarged view of a pontoon deck surface showing embossments matching the cross-sectional shape of the circular cells in the core;

FIG. 3 is a perspective view of a swim platform or diving raft as another representative product application of the present invention;

FIG. 4 is a perspective view of a dock as another representative product application of the present invention;

FIGS. 5A-C are top plan schematic views, partially broken away, of different configurations, e.g., honeycomb-like, of cellular cores;

FIG. 6 is an exploded, side sectional view showing a sandwich-type composite panel with a first skin of a fiber-reinforced thermoplastic material, a first sheet of thermoplastic adhesive, a second skin of fiber-reinforced thermoplastic material, a second sheet of thermoplastic adhesive and a cellular core of a cellulose-based material positioned between the skins;

FIG. 7 is an exploded, side sectional view showing a sandwich-type composite panel with first skin of thermoplastic material, a second skin of thermoplastic material, and a cellular core of thermoplastic material positioned between the skins;

FIG. 8 is a schematic, side sectional view showing a fluid pressure-assisted compression mold useful in facilitating debossing of the of the upper surface of the molded composite component to enhance its surface traction;

FIG. 9 is a top perspective view, in cross section, of the composite component of FIG. 6, with debossments, by application of fluid pressure;

FIG. 10 is a schematic, side sectional view showing a vacuum pressure-assisted compression mold useful in facilitating embossing of the of the upper surface of the molded composite component to enhance its surface traction;

FIG. 11 is a top perspective view, in cross section, of the composite component of FIG. 6, with embossments, by application of vacuum pressure;

FIG. 12 is a cross-sectional view, partially broken away, of a marine deck member of the present invention having a fastener component mounted within.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

FIG. 1 shows a pontoon boat 10 as a representative application of the present invention. The deck 12 can be composed of modular panels or tiles fitted to the surface configuration of the pontoon boat. The deck 12 has mounted on it conventional surface cleats 14 to facilitate docking. In addition to pontoon boat decks, the present invention is also suited for other marine applications where enhanced surface traction is desired, for example, docks, diving boards, swim platform, watercraft docking stations and the like.

FIG. 2A is a close-up view of the encircled portion of the pontoon deck 12 of FIG. 1. The deck surface has a pattern of debossments, formed with the assistance of pressurized gas in the process of compression molding the marine deck. The shape of the debossment 16 corresponds to the cross-sectional shape of the cell in the cellular core used in the composite molding.

FIG. 2B is a close-up view of an alternative embodiment of a pontoon deck surface 12′ showing embossments 16′ matching the cross-sectional shape of the circular cells in the core. The embossments 16′ are formed with the assistance of vacuum pressure in the process of compression molding the marine deck.

FIG. 3 shows the marine deck surfaces of the present invention applied with a swim platform (or diving raft) 20. The deck 12 or 12′ can be formed with debossments or embossments, respectively, as discussed below.

FIG. 4 shows the marine deck surfaces of the present invention applied with to the deck surface of a dock 22. Again, the deck 12 or 12′ can be formed with debossments or embossments, respectively, as discussed below.

FIGS. 5A-5C show exemplary surface shapes for the debossments and embossments to be formed in the marine deck surface, whether a watercraft deck, swim platform, dock, or other application. FIG. 5A shows circular shapes for debossments 16C, or circular embossments 16C′. FIG. 5B shows honeycomb shapes for debossments 16H, or honeycomb embossments 16H′. FIG. 5C shows rectangular shapes for debossments 16R, or rectangular embossments 16R′. The surface shape of the debossments or embossments will correspond to the cross-sectional shape of the cells in the core of the sandwich-type structure.

FIG. 6 is an exploded side view of the constituent parts of the composite panel 32 preparatory to compression molding. As shown in FIG. 6, a stack includes first and second reinforced thermoplastic skins or outer layers 24 and 26, respectively, a plastic core 30 having a large number of cells disposed between and bonded to plies or films or sheets of hot-melt adhesive (i.e. thermoplastic adhesive) 28 which, in turn, are disposed between and bonded to the skins 24 and 26 by compression molding. The sheets 28 may be bonded to their respective skins 24 and 26 prior to the press molding or are preferably bonded during the press molding. The thermoplastic of the sheets 28 is typically compatible with the thermoplastic of the skins 24 and 26 so that a strong bond is formed therebetween. One or more other plastics may also be included within the adhesive of the sheets 28 to optimize the resulting adhesive 24 and 26 and their respective sheets or film layers 28 (with the core 30 layers 28) are heated typically outside of a mold (i.e. in an oven) to a softening temperature wherein the hot-melt adhesive becomes sticky or tacky. The mold is preferably a low-pressure, compression mold which performs a thermo-compression process on the stack of materials.

The sticky or tacky hot-melt adhesive 28 extends a small amount into the open cells during the thermo-compression process. The skins 24 and 26 are bonded to the top and bottom surfaces of the core 30 by the sheets 28 to seal the cells of the core 30 to the facing surfaces of the skins 24 and 26.

The step of applying the pressure compacts and reduces the thickness of the cellular core 30 and top and bottom surface portions of the cellular core penetrate and extend into the film layers 28 without penetrating into and possibly encountering any fibers located at the outer surfaces of the skins 24 and 26 thereby weakening the resulting bond.

Each of the skins 24 and 26 may be fiber reinforced. The thermoplastic of the sheets or film layers 28, and the skins 24 and 26 may be polypropylene. Alternatively, the thermoplastic may be polycarbonate, polyimide, acrylonitrile-butadiene-styrene as well as polyethylene, polyethylene terphthalate, polybutylene terphthalate, thermoplastic polyurethanes, polyacetal, polyphenyl sulphide, cyclo-olefin copolymers, thermotropic polyesters and blends thereof. At least one of the skins 24 or 26 may be woven skin, such as polypropylene skin. Each of the skins 24 and 26 may be reinforced with fibers, e.g., glass fibers, carbon fibers, aramid and/or natural fibers. At least one of the skins 24 and 26 can advantageously be made up of woven glass fiber fabric and of a thermoplastics material.

The cellular core 30 of the FIG. 6 embodiment may be a cellulose-based honeycomb core. In this example, the cellular core has an open-celled structure of the type made up of a tubular honeycomb. The axes of the cells are oriented transversely to the skins 24 and 26.

The stack of material may be pressed in a low pressure, cold-forming mold 42 shown schematically in cross-section in FIG. 8. The mold has halves 44 and 46, which when closed have an internal cavity for the stack. The stack is made up of the first skin 24, the adhesive layers 28, the cellulose-based cellular core 30, and the second skin 26, and is pressed at a pressure lying in the range of 10×105 Pa. to 30×105 Pa. The first and second skins 24 and 26, and the first and second film layers 28 are preferably pre-heated to make them malleable and stretchable. Advantageously, in order to soften the first and second skins 24 and 26, and their respective film layers 28, heat is applied to a pre-assembly made up of at least the first skin 24, the first and second film layers 28, the cellular core 30, and the second film layer 26 so that, while the composite panel 32 is being formed in the mold, the first and second skins 24 and 26 and the film layers 28 have a forming temperature lying approximately in the range of 160° C. to 200° C., and, in this example, about 180° C.

Air in the sealed cavities urges softened portions of the sheets 24 and 26 and portions of the core 30 inwardly towards the cavities of the core 30.

The mold 42 is formed with a pattern of fluid passageways 50, aligned with the cell openings, to permit the application of fluid pressure onto the surface of the first skin 24 from a fluid pressure source 48. The applied fluid pressure augments the tendency of the sheets to deboss in the area above the cells. The pressure level and duration can be selected to determine the depth of the debossments 16 formed in the outer surface of the first skin 24. The debossments 16 enhance the surface traction of the outer surface of the skin 24.

FIG. 9 shows a composite panel 52 with the debossments 16R formed in rectangular shapes. The cells in the core 30 are similarly rectangular in cross-section. The outer surface of the first skin 24 has enhanced surface traction. The outer surface of the second skin 26 may be naturally debossed, but it will not be visible as part of a marine deck member.

FIG. 8 is an exploded side view of the constituent parts of an alternative embodiment of a composite panel 40 preparatory to compression molding. In this embodiment, thermoplastic skins 34 and 36 are bonded to a thermoplastic core 38 in sealed relation by heating to the softening point of the plastic. The stack may be preheated, or heated in the mold.

The core may be injection molded by the process disclosed in U.S. Pat. No. 7,919,031, titled “Method And System For Making Plastic Cellular Parts And Thermoplastic Composite Articles Utilizing Same,” commonly assigned to the assignee of the present invention.

A stack whether in the embodiment of stack 32 in FIG. 6, or the stack 40 of FIG. 7, may be formed with either debossments, per the mold configuration of FIG. 8, or formed with embossments, per the mold configuration of FIG. 10.

In FIG. 10, the mold 68 is equipped with a vacuum source 66 to apply vacuum pressure through channels 70 to the outer surface of the plastic skin 24 while the skin is heated and formable in the mold.

The application of sufficient vacuum pressure causes the outer surface of the skin 24 to the raised with embossments 16 R on the composite panel. In this case the embossments 16R are rectangular in shape to correspond with the cross-sectional shape of the cells in the core 30. The outer surface of the skin 24 has enhanced surface traction due to the embossments.

FIG. 12 shows the mounting of a fastener component 80 in the composite panel 32. The fastener component can be used to secure cleats 14 to a marine deck formed of the inventive composite panel.

After compression or press molding, at least one hole is formed in the composite panel 52 such as by cutting through the first skin 24, through the core 30 right up to but not through the second skin 26. A rivet-like fastener such as the fastener component 80 is positioned in the hole. Each fastener component 80 is generally of the type shown in U.S. Pat. No. 7,713,011 and 2007/0258786 wherein the preferred fastener component is called an M4 insert, installed by use of a hydro-pneumatic tool both of which are available from Sherex Fastening Solutions LLC of New York. During installation, an outer sleeve 44 of the fastener component 50 is deformed, as shown in FIG. 7.

The fastener component 80 typically has a relatively large annular flange, generally included at 82, with a plurality of integrally formed locking formations or wedges (not shown) circumferentially spaced about a central axis of the component 80 on the underside of the flange 82 to prevent rotary motion of the fastener component 80 relative to the first skin 24 after installation. The wedges grip into the outer surface of the first skin 24 after the fastener component 80 is attached to the first skin 24.

A fastener 80 of the type illustrated in FIG. 12 can withstand (i) large pull-out forces, (ii) large push-in forces, and large rotational forces (torque). These performance criteria must be met while preserving the mechanical and aesthetic properties of the composite panel 52. Additionally, in this use environment, the underside of the composite panel 32 must remain impervious to moisture absorption. Moisture absorption may result in increased weight and performance degradation over a prolonged period, especially on the underside of a marine deck.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. 

What is claimed is:
 1. A method of making a sandwich-type, compression-molded, composite panel having enhanced surface traction for use as a marine deck member, the method comprising: heating a stack of sandwich material including first and second plastic skins and a plastic core positioned between the skins, the core having a plurality of cells whose axes are oriented transversely to the skins, the skins and the core being heated to a softening temperature of the plastic; providing a compression mold including panel-forming, upper and lower dies, which when closed, define a mold cavity having a shape substantially corresponding to a desired shape of the panel; placing the stack on the lower die in an open position of the mold; moving the dies toward each other until the mold is in a closed position; allowing the heated stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core to seal the core cells, air in the sealed cells urging softened portions of the skins inwardly towards the cells of the core as the air in the cells cools; and applying pressurized gas at a first outer surface of the stack in the mold cavity to facilitate debossing and enhance the surface traction of the first outer surface.
 2. The method of claim 1 wherein the stack is heated in the compression mold.
 3. The method of claim 1 wherein the stack is heated prior to being placed in the compression mold.
 4. A method of making a sandwich-type, compression-molded, composite panel having enhanced surface traction for use as a marine deck member, the method comprising: heating a stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and between the sheets, the core having a plurality of cells oriented transversely to the skins, the skins, the sheets and the core being heated to a softening temperature of the thermoplastics; providing a compression mold including upper and lower, which when closed, define a mold cavity having a shape substantially corresponding to a desired shape of the panel; placing the stack on the lower die in an open position of the mold; moving the dies toward each other until the mold is in a closed position; and allowing the heated stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal the core cells, air in the sealed cells urging softened portions of the sheets and portions of the core inwardly towards the cells of the core as the air in the cells cools; and applying pressurized gas at a first outer surface of the stack in the mold cavity to facilitate debossing and enhance the surface traction of the first outer surface.
 5. The method of claim 4 wherein the stack is heated in the compression mold.
 6. The method of claim 4 wherein the stack is heated prior to being placed in the compression mold.
 7. A marine deck member having enhanced surface traction made by a method comprising the steps of: heating a stack of sandwich material including first and second plastic skins and a plastic core positioned between the skins, the core having a plurality of cells whose axes are oriented transversely to the skins, the skins and the core being heated to a softening temperature of the plastic; providing a compression mold including panel-forming, upper and lower dies, which when closed, define a mold cavity having a shape substantially corresponding to a desired shape of the panel; placing the stack on the lower die in an open position of the mold; moving the dies toward each other until the mold is in a closed position; allowing the heated stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core to seal the core cells, air in the sealed cells urging softened portions of the skins inwardly towards the cells of the core as the air in the cells cools; and applying pressurized gas at a first outer surface of the stack in the mold cavity to facilitate debossing and enhance the surface traction of the first outer surface.
 8. A marine deck member having enhanced surface traction made by a method comprising the steps of: heating a stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and between the sheets, the core having a plurality of cells whose axes are oriented transversely to the skins, the skins and the thermoplastic adhesive layers being heated to a softening temperature; providing a compression mold including panel-forming, upper and lower dies, which when closed, define a mold cavity having a shape substantially corresponding to a desired shape of the panel; placing the stack on the lower die in an open position of the mold; moving the dies toward each other until the mold is in a closed position; allowing the heated stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded by the thermoplastic adhesive to top and bottom surfaces of the core to seal the core cells, air in the sealed cells urging softened portions of the skins inwardly towards the cells of the core as the air in the cells cools; and applying pressurized gas at a first outer surface of the stack in the mold cavity to facilitate debossing and enhance the surface traction of the first outer surface.
 9. A marine deck member comprising: a compression-molded composite component having a sandwich structure, the component including: a load-bearing, reinforced plastic, first outer layer; a reinforced plastic, second outer layer; and a low density, cellular core positioned between the outer layers and having a plurality of sealed cells wherein the outer layers and the core are bonded into a unitary structure by press molding; at least one fastener component, each fastener component including: a fastener part having a length, a width and an axis defined as being central to the fastener part; and a mounting part mounting the fastener part to the first outer layer, the mounting part having a pair of holding faces that oppose each other and define a space therebetween, a portion of the first outer layer being positioned in the space in engagement with the faces to prevent the fastener part from moving along its length relative to the first outer layer; and an opening which extends completely through the first outer layer and at least partially extends through the core towards the second outer layer but not through the second outer layer, wherein the opening terminates so as to leave the second outer layer impervious at the opening, wherein the mounting part mounts the fastener component in the opening.
 10. A marine deck member comprising: a compression-molded composite component having a sandwich structure, the component including: a load-bearing, reinforced plastic, first outer layer; a reinforced plastic, second outer layer; and a low density, cellular core positioned between the outer layers and having a plurality of sealed cells wherein the outer layers and the core are bonded into a unitary structure by press molding.
 11. A marine deck member comprising: a compression-molded composite component having a sandwich structure including first and second reinforced thermoplastic skins defining first and second outer layers, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and the sheets and having a plurality of sealed cells, wherein the skins, adhesive and core are bonded into a unitary structure by press molding.
 12. The marine deck member of claim 11 wherein the plurality of cells are oriented transversely to the skins and the surface traction of the first outer layer is enhanced by applying pressurized gas onto the first outer layer in the mold cavity to facilitate debossing.
 13. A pontoon boat deck comprising: a compression-molded composite deck having a sandwich structure, the deck including: a load-bearing, reinforced plastic, first outer layer; a reinforced plastic, second outer layer; and a low density, cellular core positioned between the outer layers and having a plurality of cells wherein the outer layers and the core are bonded into a unitary structure by press molding.
 14. The pontoon boat deck of claim 13 wherein the plurality of cells are oriented transversely to the skins and the surface traction of the first outer layer is enhanced by applying pressurized gas onto the first outer layer in a press molding process to facilitate debossing.
 15. The pontoon boat deck of claim 13 wherein the compression-molded composite component is formed of a plurality of press-molded panels having the sandwich structure, the panels being fitted to the surface configuration of the deck. 